Efficiency and Calculation Guide

4.2. Consumable Consumption and Welding Time 4.2.1 Calculation of Electrode Consumption
Calculation Formula For the practical welder it is important to be able to estimate the requirement for stick electrodes or other filler metals quickly, easily and accurately enough. The following pages illustrate a simplified method which is intended above all to make an initial estimate possible. An accurate calculation is not possible using generally applicable tables as the tables would become too complicated and therefore unmanageable. The following approach may be used as the calculation formula: Weight of weld without weld reinforcement x x = / x x x = Factor for the effect of the welding position (weld reinforcement) Allowance for back welding (if necessary) Reference value for the total weight of the weld 0.01894 kg/pcs. = weight of core metal rod deposited (3.2/350, stub 50 mm, metal recovery 100%) Factor for divergent electrode dimension Factor for divergent metal recovery Factor for divergent stub length Reference value for the number of electrodes required

The individual lines of the calculation formula are explained in a little more detail in the following sections and are provided with summaries in the form of tables. The method of proceeding is demonstrated briefly at the end of the section using a practical example. Weight of Weld The following tables provide an overview of the weight of the weld for different welding procedures with different types of welds. The weld shapes correspond to the specifications of the standard. Recommended diameters for rods and electrodes should only be considered as reference values. The data will be too high above all in the out-of-position welds. The weights of weld metals correspond as they only relate to the cross-section to be filled. reference values for gas welding of flat-position joints (one side, without backing) thickness mm 0.8 1.0 edge air gap preparation mm I I 0 0 rod diameter mm 1.5 2.0 deposition rate kg/h 0.17 0.19 weight of joint kg/m 0.024 0.024 welding time min/m 8.5 7.6

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Efficiency and Calculation Guide

thickness mm 1.5 2.0 3.0 4.0 5.0 6.0 edge air gap preparation mm I 1.5 I 2.0 I 2.5 I 3.0 I 4.0 V 60 3.0 rod diameter mm 2.0 2.0 2.5 3.2 3.2 3.2 deposition rate kg/h 0.25 0.25 0.36 0.70 0.74 0.80 weight of joint kg/m 0.042 0.048 0.074 0.17 0.265 0.35 welding time min/m 10.0 11.5 12.3 14.5 21.5 25.5

reference values for shielded manual arc welding of butt welds (without backing, flat) thickness mm air gap mm number of layers electrode dimension mm deposition rate kg/h weight of joint kg/m welding time per layer min/m

1.5 0 1 2.5/250 0.5 0.03 3.6 2.0 0 1 2.5/250 0.61 0.036 3.5 3.0 2 1 3.2/350 0.53 0.064 7.25 For double-vee welds it is possible to find a usable reference value for back welding on the root side of the weld by doubling the corresponding vee weld values of half the sheet thickness and adding the weight of the weld. Back welding on the root side of the weld is assessed with approximately half the weight of the root for sheet thicknesses under 8 mm and the simple weight of the root for thicker sheets. reference values for shielded manual arc welding of fillet welds (one side, horizontal) thickness a mm 3.0 4.0 5.0 6.0 7.0 8.0 10.0
l layer

number of layers 1 1 1 3 3 3 3

electrode dimension mm 3.2/350 5.0/450 6.0/450 4.0/450+ 3.2/350 4.0/450 4.0/450 4.0/450

deposition rate kg/h 1.19 1.75 2.14 1.+2.l: 1.38 3.l: 0.88 1.+2.l: 1.38 3.l: 1.25 1.+2.l: 1.38 3.l: 1.25 1.42

weight of joint kg/m 0.085 0.145 0.21 1.+2.l: 0.19 3.l: 0.11 1.+2.l: 0.31 3.l: 0.11 1.+2.l: 0.37 3.l: 0.18 1.l: 0.29 2.l: 0.31 3.l: 0.25

welding time per layer min/m 4.3 5.0 5.9 1.+2.: 8.3 3.: 7.5 1.+2.: 13.5 3.: 6.8 1.+2.l: 16.1 3.l: 8.6 1.l: 12.2 2.l: 13.1 3.l: 10.5

reference values for shielded manual arc welding of flat vee-welds of plates thickness mm 4.0 5.0 6.0 7.0 ace/gap mm 2/1 2/1 2/1 2.5/1.5 2 2 3 3 number of layers electrode dimension mm r 2.5/250 c 3.2/350 r 2.5/250 c 4.0/450 r 2.5/250 f,c 3.2/350 r 3.2/350 f,c 4.0/450 deposition rate kg/h r 0.43 c 1.2 r 0.48 c 1.41 r 0.52 f,c 1.24 r 0.75 f,c 1.38 weight of joint kg/m r 0.08 c 0.09 r 0.085 c 0.105 r 0.08 f+c 0.14 r 0.14 f+c 0.22 welding time per layer min/m r 11.2 c 4.5 r 10.6 c 4.5 r 9.2 f+c 6.8 r 11.2 f+c 9.2

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Efficiency and Calculation Guide

reference values for shielded manual arc welding of flat vee-welds of plates thickness mm 8.0 9.0 10.0 12.0 15.0 face/gap mm 3/2 3/2 3/2 3.5/2 3.5/2 3 3 4 5 5 number of layers electrode dimension mm r 3.2/350 f 4.0/450 c 5.0/450 r 3.2/350 2f,c 5.0/450 r 3.2/350 3f,c 5.0/450 r 3.2/350 3f,c 5.0/450 r 3.2/350 3f,c 5.0/450 deposition rate kg/h r 0.75 f 1.42 c 1.75 r 0.75 f,c 1.88 r 0.75 f,c 1.88 r 0.75 f,c 1.93 r 0.81 f,c 2.1 weight of joint kg/m r 0.16 f 0.13 c 0.14 r 0.14 f+c 0.37 r 0.15 f+c 0.47 r 0.17 f+c 0.74 r 0.15 f+c 0.91 welding time per layer min/m r 12.8 f 5.5 c 4.8 r 11.2 f+c 11.8 r 12.0 f+c 15.0 r 13.6 f+c 23.0 r 11.1 f+c 26.0

r .. root pass, f .. filler layer, c .. cap layer

For double-vee welds it is possible to find a usable reference value for back welding on the root side of the weld by doubling the corresponding vee weld values of half the sheet thickness and adding the weight of the weld. Back welding on the root side of the weld is assessed with approximately half the weight of the root for sheet thicknesses under 8 mm and the simple weight of the root for thicker sheets.

Effect of the Welding Position The welding position has different effects on the execution of a weld. It is not possible to disregard the welding position for calculating quantities as in affects the weld reinforcement. When estimating time effects are to be anticipated due to higher downtimes such as cleaning, electrode replacement, lower current intensities, etc. The following tables provide rough reference values in the form of multipliers which may be used to adapt the weight of the weld for horizontal position from the first determination.

factors for divergent welding positions - weight vee-weld fillet weld PB 1.0 1.0 PA 1.0 0.95 PG 1.0 1.0 PE 1.1 1.1 PF 1.15 1.05 PC 1.15 1.0

factors for divergent welding positions - welding time vee-weld fillet weld PB 1.0 1.0 PA 1.0 0.95 PG 1.1 1.15 PE 1.87 1.65 PF 1.5 1.43 PC 1.2 1.1

The values highlighted correspond to the reference calculation.

Proportion of Weld Metal for Back Welds When deciding on a specific weld preparation one should not forget back welding if it is necessary for quality reasons. There are certain reference points for the consumption of filler metal and the work time required for back welding. The following list is based on practical values that were gained from experience in the grooving out of weld roots without major defective parts of the weld. The additional consumption is specified as a multiplier for the weight of the weld without back welding. The angle information refers to the weld preparation angle or the angle of bevel preparation for U-groove welds.

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Efficiency and Calculation Guide

vee-weld 60 1.27 1.19 1.18 1.14 double-vee-weld 60 90 U-groove weld 10 15

thickness mm 611 1116 1620 2130 20 30 40 60 80 90 100 120

50 1.32 1.24 1.21 1.18

90 1.15 1.11 1.10 1.08

50

1.26 1.17 1.15 1.10 1.07 1.04

1.21 1.14 1.12 1.08 1.055

1.12 1.08 1.07

1.18 1.10 1.06 1.05 1.035

1.17 1.09 1.05 1.04 1.03

1.16 1.08 1.04 1.04 1.025

1.03

Allowance for Divergent Electrode Dimensions Naturally the core metal rod deposited per electrode changes if other electrode dimensions are used for performing a weld, i.e. a considerably higher number of thinner electrodes will be required than of thicker electrodes to fill the same weld volume. A stub loss of 50 mm was taken into account for the following table and this applies to all dimensions. The metal recovery is 100 % for all dimensions.
diameter mm 1.5 2.0 2.0 2.5 2.5 3.2 3.2 3.2 4.0 4.0 5.0 6.0 length mm 250 250 300 250 300 300 350 450 350 450 450 450 allowance factor 6,83 3,84 3,07 2,46 1,97 1,20 1,00* 0,75 0,64 0,48 0,31 0,21

* reference for the approach used

Allowance for Divergent Metal Recovery The metal recovery of a stick electrode is the ratio of the weight of weld metal deposited to the weight of core rod deposited. It depends on the type of electrode (e.g. contribution of metal flux powder from the electrode coating), the diameter of the electrode (usually somewhat higher with larger diameters), the welding current (increasing or decreasing slightly with the current depending on the type of coating) and the welding position (different spatter and burn-off losses). In practical use it is sufficient to calculate using the multipliers in the following table. The table allows for standard classification in accordance with EN and the type of coating if greater deviations are to be reckoned with.

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Efficiency and Calculation

code acc. EN 1 and 2 type of coating C R, RC RR B R B RA, RR, B RA, RR, B allowance factor 1.25 1.11 1.05 1.0** 0.91 0.87 0.71* 0.56*

3 and 4 5 and 6 7 and 8

* With high-performance types Bhler Weldings brand designation provides a reference to the actual metal recovery. The multiplier should be corrected accordingly (e.g. 0.62 for FOX HL 160 Ti). ** Reference for the approach used

Allowance for Divergent Stump Losses When determining the number of electrodes from the required weight of weld metal, allowance must also be made for the electrode stubs in addition to the losses included in metal recovery. The following table shows that with regard to the electrode requirement for a specific quantity of weld metal, the varying stub losses for which the welder is responsible have a greater effect on the calculation than variations in the metal recovery of a specific type of electrode. In the case of stub lengths allowance must be made for the fact that the welder is not always wholly able to influence them. For example restricted access to the weld may easily lead to stub lengths over 80 mm. In this case the designer is responsible for ensuring good access. Out-of-position welds also result in longer stubs than welds in the gravity position.
diameter mm 1.5 2.0 2.0 2.5 2.5 3.2 3.2 3.2 4.0 4.0 5.0 6.0 length mm 250 250 300 250 300 300 350 450 350 450 450 450 40 allowance factor for different stub length values in mm 50 60 70 80 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.05 1.05 1.04 1.05 1.04 1.04 1.03 1.03 1.03 1.03 1.03 1.03 1.11 1.11 1.09 1.11 1.09 1.09 1.07 1.05 1.07 1.05 1.05 1.05 1.18 1.18 1.14 1.18 1.14 1.14 1.11 1.08 1.11 1.08 1.08 1.08

0.95 0.95 0.96 0.95 0.96 0.96 0.97 0.98 0.97 0.98 0.98 0.98

Example for Calculation

A metal sheet with a thickness of 15 mm is to be joined in the horizontal-vertical position. Let the weld length be 10 m. A vee weld with a preparation angle of 60 is chosen as the weld preparation. For quality assurance reasons the root will be back welded. A basic stick electrode will be used (the metal recovery code according to EN is 4). An electrode with 3.2 mm will be used for the root and an electrode with 4.0 mm will be used for the filler and cover passes. The stub length is assumed to be 70 mm.

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Efficiency and Calculation Guide

influencing factor weight of weld without weld reinforcement x factor for the effect of the welding position (weld reinforcement) x allowance for back welding (if necessary) reference value for the total weight of the weld / 0.01894 kg/pcs. = weight of core metal rod deposited (3.2/350, stub 50 mm, metal recovery 100%) x factor for divergent electrode dimension x factor for divergent metal recovery x factor for divergent stub length reference value for the number of electrodes required
r .. root pass, f .. filler layer, c .. cap layer

calculated values r f+c 0.15x10 = 1.5 kg 0.91x10 = 9.1 kg 1.15 1.19 2.05 kg 12.45 kg 0.01894 1.0 0.48 0.87 1.07 1.05 101 Stk. 289 Stk.

r f+c

r f+c r f+c r f+c

Explanations The weight of the weld may be taken from the table Reference Values for Manual Metal Arc Welding of Horizontal Vee Welds in Sheet Metal. This table is already divided into root, filler and cover passes for assistance. The factor for the influence of the welding position may be found in the appropriate section. The same applies to back welding of the root in which case the value is chosen depending on the thickness of the sheet, the shape of the weld and the weld preparation angle.
From this information the total weight of the weld should be determined divided into areas for different electrode dimensions. The next line produces the number of electrodes if only one electrode with 3.2/350 with 50 mm stub and 100 % metal recovery were to be used. As a thicker electrode is used for the filler and cover passes, allowance must be made for the altered electrode dimension. Let the metal recovery be 115 %, which would result in a factor of 1/1.15 = 0.87. The altered stub length results in different effects depending on the electrode length. The number of electrodes required as a result of division and multiplication is only a reference value to which a factor must be added for any waste due to bent, contaminated or incompletely used electrodes.

4.2.2 Estimation of Standard Welding Time

Actual Welding Time Reduction of the costs by reducing the actual welding time is one of the most important tasks of production monitoring. In this case the actual welding time may be estimated within certain limits. However, a second factor that has just as great a significance for reduction of the overall costs is increasing the proportion of actual welding time in the overall time. The approach shown here uses part of the calculation for the requirement of filler metal and the deposition rate of the individual electrodes. = / / x = reference values for total weight of joint in kg deposition rate of consumable in kg/(h*A) chosen amperage in A 60 min/h reference values for welding time in minutes

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Efficiency and Calculation Guide

The deposition rate is not shown for every single brand as the divergence resulting from the different welding conditions does not justify this level of detail. The following table presents a summary of deposition rates for different types of coating. In the case of ranges of values the lower value in each case should be assigned to the lower current intensity limit for this electrode. type of stick electrode deposition rate [kg/(h*A)] 2.5 mm 3.2 mm 4.0 mm 0.009-0.015 0.010-0.011 0.009 0.009 0.009 0.01 0.011 0.009 0.01 0.01 0.013 0.015 0.017 0.02 0.011 0.009 0.01 0.01 0.011 0.009 0.011 0.011 0.014 0.016 0.018 0.021 0.01 0.011 0.011 0.015 0.016

1.5 mm

2.0 mm 0.009 0.01 0.008 0.009-0.0091 0.008

5.0 mm

6.0 mm

medium coated (rutile) R 0.01 RC thick coated (rutile) RR RC 0.009 AR RB thick coated (basic) B R(B) metal powder type RR (160 %) RR (180 %) RR (200 %) RR (240 %) AR (120 %) Example for Calculation

0.008 0.009 0.009 0.009 0.01-0.011 0.011 0.008-0.009 0.008-0.009 0.009-0.010 0.009 0.01 0.01 0.012 0.014 0.016 0.012-0.014 0.011

A metal sheet with a thickness of 15 mm is to be joined in the horizontal-vertical position. Let the weld length be 10 m. A vee weld with a preparation angle of 60 is chosen as the weld preparation. For quality assurance reasons the root will be back welded. A basic stick electrode will be used (the metal recovery code according to EN is 4). An electrode with 3.2 mm will be used for the root and an electrode with 4.0 mm will be used for the filler and cover passes. The stub length is assumed to be 70 mm. Thus the example is identical to the example for estimating the electrode requirement. The electrode is specified more particularly as BHLER FOX EV 50 to obtain a calculation variable. influencing factor weight of weld without weld reinforcement x factor for the effect of the welding position (weld reinforcement) x allowance for back welding (if necessary) reference value for the total weight of the weld / deposition rate of consumable in kg/(h*A) / chosen amperage in A x 60 min/h reference values for welding time in minutes
r .. root pass, f .. filler layer, c .. cap layer

calculated values r 0.15x10 = 1.5 kg f+c 0.91x10 = 9.1 kg 1.15 r f+c r f+c r f+c 1.19 2.05 kg 12.45 kg 0.010 110 160 60 112 min 467 min

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Efficiency and Calculation Guide Duty Cycle The proportion of actual welding time is often referred to as the duty cycle. This value specified in percent does not make any statement as an absolute variable about the efficiency of a method of working since with high-performance procedures where it is not possible to reduce the downtimes to the same extent as the actual welding time for example, the duty cycle may actually drop in percentage despite the total welding time being lower. The downtimes that reduce the duty cycle may be dependent on the procedure, component, operating environment and the welder himself. The individual aspects are not dealt with in greater detail here. In any case an accurate analysis is required to find reference points for reducing the downtimes. For the calculation of standard times attempts have been made time and again to specify reference values for the duty cycle. Values of this type range for example from 5 % for tack welds in assembly to over 30 % for individual production of machine casings and 55 % for series production of machine casings up to 70 % for series production of components in turnover jigs. One may not overlook in this case that these figures have to be checked individually for each company or have to be compared with in-house statistics since investigations of different sizes of company in different sectors showed divergences in the average duty cycle between 30 and 75 %. With statistically well-covered duty cycle values the standard time is calculated as follows: Standard time = actual welding time / duty cycle x 100

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Helpful Tools

5 Comparison Table for Hardness

Rm HV HB HRC Rm 200 210 220 225 230 240 250 255 260 270 280 285 290 300 305 310 320 330 335 340 350 360 370 380 385 390 400 410 415 420 430 440 450 460 465 470 480 490 495 500 510 520 530 540 HV 63 65 69 70 72 75 79 80 82 85 88 90 91 94 95 97 100 103 105 107 110 113 115 119 120 122 125 128 130 132 135 138 140 143 145 147 150 153 155 157 160 163 165 168 Tensile Strength in N/mm2 Vickers-Hardness Brinell-Hardness Rockwell-C-Hardness HB 60 62 66 67 68 71 75 76 78 81 84 86 87 89 90 92 95 98 100 102 105 107 109 113 114 116 119 122 124 125 128 131 133 136 138 140 143 145 147 149 152 155 157 160 HRC --------------------------------------------Rm 545 550 560 570 575 580 590 595 600 610 620 625 630 640 650 660 670 675 680 690 700 705 710 720 730 740 750 755 760 770 780 785 790 800 810 820 830 835 840 850 860 865 870 880 HV 170 172 175 178 180 181 184 185 187 190 193 195 197 200 203 205 208 210 212 215 219 220 222 225 228 230 233 235 237 240 243 245 247 250 253 255 258 260 262 265 268 270 272 275 HB 162 163 166 169 171 172 175 176 178 181 184 185 187 190 193 195 198 199 201 204 208 209 211 214 216 219 221 223 225 228 231 233 235 238 240 242 245 247 249 252 255 257 258 261 HRC ------------------------------21 22 23 24 25 26 Rm 890 900 910 915 920 930 940 950 960 965 970 980 990 995 1000 1010 1020 1030 1040 1050 1060 1070 1080 1090 1095 1100 1110 1120 1125 1130 1140 1150 1155 1160 1170 1180 1190 1200 1210 1220 1230 1240 1250 1255 HV 278 280 283 285 287 290 293 295 299 300 302 305 308 310 311 314 317 320 323 327 330 333 336 339 340 342 345 349 350 352 355 358 360 361 364 367 370 373 376 380 382 385 388 390 HB 264 266 269 271 273 276 278 280 284 285 287 290 293 295 296 299 301 304 307 311 314 316 319 322 323 325 328 332 333 334 337 340 342 343 346 349 352 354 357 361 363 366 369 371 HRC 27 28 29

30 31 32 33 34

35

36

37 38 39

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